Foldable Box

ABSTRACT

A foldable box having a first, substantially flat and unfolded configuration which can be easily and conveniently transformed into a second, three-dimensional configuration capable of retaining one or more items.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the priority benefit of U.S. Provisional Patent Application Ser. No. 62/428,602, filed Dec. 1, 2016, U.S. Provisional Patent Application Ser. No. 62/428,606, filed Dec. 1, 2016, U.S. Provisional Patent Application Ser. No. 62/476,914, filed Mar. 27, 2017; U.S. Provisional Patent Application Ser. No. 62/485,091, filed Apr. 13, 2017; and is a continuation-in-part of U.S. patent application Ser. No. 29/583,811 filed Nov. 9, 2016; U.S. patent application Ser. No. 29/583,815 filed Nov. 9, 2016; U.S. patent application Ser. No. 29/585,394 filed Nov. 23, 2016; U.S. patent application Ser. No. 29/585,399 filed Nov. 23, 2016; U.S. patent application Ser. No. 29/610,397 filed Jul. 12, 2017; U.S. patent application Ser. No. 29/611,998 filed Jul. 27, 2017; U.S. patent application Ser. No. 29/612,002 filed Jul. 27, 2017; U.S. patent application Ser. No. 29/611,995 filed Jul. 27, 2017; U.S. patent application Ser. No. 29/611,992 filed Jul. 27, 2017; U.S. patent application Ser. No. 29/623,678 filed Oct. 26, 2017; U.S. patent application Ser. No. 29/623,680 filed Oct. 26, 2017; U.S. patent application Ser. No. 29/623,683 filed Oct. 26, 2017; U.S. patent application Ser. No. 29/623,686 filed Oct. 26, 2017; U.S. patent application Ser. No. 29/623,688 filed Oct. 26, 2017; U.S. patent application Ser. No. 29/623,689 filed Oct. 26, 2017; U.S. patent application Ser. No. 29/623,693 filed Oct. 26, 2017; U.S. patent application Ser. No. 29/627,144 filed Nov. 22, 2017; U.S. patent application Ser. No. 29/613,487 filed Aug. 10, 2017; and U.S. patent application Ser. No. 29/613,491 filed Aug. 10, 2017, all of which are incorporated herein by reference.

A foldable box having a first, substantially flat and unfolded configuration which can be easily and conveniently transformed into a second, three-dimensional configuration capable of retaining one or more items.

BACKGROUND ON THE INVENTION

Boxes are used every day for many purposes such as storage and shipping. Typically, when boxes are manufactured by a manufacturing company, the boxes are manufactured and shipped in a three-dimensional form. The manufacturing company then must pay for additional shipping cost for empty space within the box. Additionally, the boxes are also more susceptible to damage when shipped in this fashion. To overcome the high shipping cost and inefficient shipping of such boxes, box designers have made collapsible boxes. These boxes are designed to be shipped flat and need to be constructed by the end user of the box. End user construction of these boxes often requires time-consuming processes such as the application of additional or extra materials (e.g., glue, tape, etc.). These actions can be complicated, time-consuming, and labor intensive to the end user, thereby making the assembly of such boxes undesirable.

Non-limiting examples of such prior art foldable boxes include U.S. Patent Publication Nos. 2004/0140345; 2006/0151856; 2010/0006632; 2011/0121062; 2012/0037693 and 2014/0231495, and U.S. Pat. Nos. 2,957,617; 6,568,586; 8,573,471; 8,960,527 and RE 46563, all of which are incorporated herein by reference.

In view of the current state of foldable boxes, there is a need for a foldable box having one or more interchangeable configurations, and which can be easily and conveniently transformed between such interchangeable configurations thereby minimizing the time required for assembly and/or disassembly of the foldable box.

SUMMARY OF THE INVENTION

The present invention is directed to a foldable box having one or more interchangeable configurations, and which can be easily and conveniently transformed between such interchangeable configurations, thereby minimizing the time required for assembly and/or disassembly of the foldable box.

In one non-limiting aspect of the present invention, there is provided a foldable box having a plurality of interchangeable configurations. In one non-limiting aspect of the present invention, there is provided a foldable box having a first, unfolded configuration in which the foldable box is substantially flat, and a second, folded and/or three-dimensional configuration in which the foldable box is fully assembled.

Referring now to FIGS. 1-39, there is illustrated a foldable box in accordance with another and/or alternative non-limiting aspect of the present invention. Referring now to FIGS. 1-13, the foldable box is foldable between one or more interchangeable configurations, and can be easily and conveniently transformed therebetween. The foldable box can be used as a file storage box; however, the foldable box can be used for other or alternative applications. In one non-limiting aspect of the present invention, the foldable box has a first, unfolded configuration in which the foldable box is substantially flat, and a second, folded and/or three-dimensional configuration in which the foldable box is fully assembled. The first configuration (i.e. the flat, unfolded foldable box) can be easily and conveniently transformed into the second configuration (i.e. the folded, three-dimensional foldable box) and, similarly, the second configuration can be easily and conveniently transferred into the first configuration; however, this is not required. In one non-limiting configuration, the foldable box comprises a base portion and a lid portion as separate components; however, this is not required.

The materials used to form the foldable box are non-limiting. The foldable box can be formed from a single type of material; however, this is not required. As can be appreciated, the foldable box can be formed from one or more types of material. Generally, the foldable box is formed from a moderately rigid material such as, for example, a heavy weight cardboard material or paperboard material; however, this is not required. As can be appreciated, the foldable box can be formed from other or alternative materials (e.g., flexible materials, semi-rigid materials, medium weight cardboard, fiberboard, rigid plastic, flexible plastic, composite materials, metal, wood, etc.). The material of the foldable box is typically selected so as to allow folding, bending, or other manipulations of the foldable box without losing the structural integrity of the material; however, this is not required. In one non-limiting configuration, the thickness of the material used to form the foldable box can be from about 0.01 mm to about 10 mm, more particularly about 2 mm; however, this is not required.

In another and/or alternative non-limiting aspect of the present invention, the material of the foldable box can be lined with one or more additional types of material; however, this is not required. In one non-limiting embodiment, the material of the lining is a laminate material; however, other or alternative liners can be used (e.g., cloth, cloth-like materials, tape, tape-like materials, plastic material, fabric material, etc.). Generally, the lining (when used) is designed to completely cover at least a first surface of the foldable box; however, this is not required. In one non-limiting configuration, the lining completely covers a first surface of a portion of the foldable box, wraps around the perimeter thereof, and terminates at a position at or near the perimeter on a second surface of the portion of the foldable box; however, this is not required. The lining can be used to provide an aesthetically pleasing appearance to the foldable box; however, this is not required. As such, the lining can include designs, surface structures, etc. on a surface thereof; however, this is not required. The lining (when used) typically has a thickness less than or equal to the material used to form the foldable box; however, this is not required. As such, the lining can be designed to provide support to the foldable box; however, this is not required. The lining can be used to connect together one or more pieces of the foldable box (e.g., connect together multiple pieces of paperboard panels that are used to form one or more sides of the foldable box, etc.), and/or be used to form a hinge or foldable region between two or more pieces of the foldable box; however, this is not required.

The shape of the foldable box is non-limiting. In one non-limiting configuration, the shape of the top plan view of the foldable box in its first, unfolded configuration is t-shaped or x-shaped; however, the shape of the top plan view of the foldable box in its first, unfolded configuration can have other shapes. From its first, unfolded configuration, the foldable box can optionally be folded into a space-saving, compact configuration in which one or more panels are folded such that the one or more panels of the foldable box are stacked on top of one another; however, this is not required. In another and/or alternative non-limiting configuration, the shape of the top plan view of the foldable box in its second, three-dimensional configuration is rectangular or square; however, the shape of the top plan view of the foldable box in its second, three-dimensional configuration can have other or alternative shapes. Similarly, the size of the foldable box in its folded and/or unfolded configuration is non-limiting. In one specific non-limiting configuration, when the foldable box in the folded configuration has a top plan rectangular shape, the dimensions of the foldable box can be about 1-24 inches in height by about 2-30 inches in width by about 1-24 inches in length; however, the foldable box can have other dimensions. In one specific non-limiting configuration, when the foldable box in the folded configuration has a top plan square shape, the dimensions of the foldable box can be about 1-20 inches in height by about 2-20 inches in width by about 2-20 inches in length; however, the foldable box can have other dimensions.

In one non-limiting aspect of the present invention, the foldable box comprises a first set of panels and a second set of panels; however, this is not required. In one non-limiting configuration, the first set of panels form the base portion of the foldable box and the second set of panels form the lid portion of the foldable box; however, this is not required. As can be appreciated, the base portion and the lid portion of the foldable box can be formed from a single set of panels; however, this is not required. The second set of panels is designed to be foldably connected to the first set of panels; however, this is not required. This non-limiting configuration provides a non-limiting advantage in that all components of the foldable box are connected such that no further assembly is required by the end user; a common disadvantage of many existing foldable box types is that at least one component must typically be assembled separately and connected to the remaining portion of a box. This non-limiting configuration also has the advantage that the foldable box, after being assembled into its folded configuration, can later be unassembled into its original unfolded position. Foldable boxes that require the permanent connection of one or more components during assembly cannot thereafter be unassembled into its original unfolded position without having to damage one or more portions of the foldable box.

In another and/or alternative non-limiting aspect of the present invention, the first set of panels further comprises a bottom panel, a front panel, a back panel, a left panel and a right panel arranged in a predetermined sequence; however, this is not required. In another and/or alternative non-limiting aspect of the present invention, the front and back panels further comprise front and back end panels, respectively, extending from opposing side edges thereof; however, this is not required. In one non-limiting configuration, the bottom panel, front panel, back panel, left panel, right panel, font end panels and back end panels are defined portions in a single piece of material; however, this is not required. In such a configuration, the bottom panel, front panel, back panel, left panel, right panel, font end panels and back end panels can be defined via cutting, scoring, creasing and/or folding; however, other or alternative methods can be used. The cutting, scoring, creasing and/or folding (when used) also provides the foldable connections between adjacent panels of the first set of panels. The size and shape of the foldable connections are non-limiting. Generally, the foldable connections are designed to permit from about 1° to about 180° angles of relative rotation between adjacent panels; however, this is not required. For example, from a flat, unfolded configuration, the connection arrangements can permit the front panel to be rotated about 90° relative to the bottom panel, the back panel to be rotated about 90° relative to the bottom panel, the right panel to be rotated about 90° relative to the top panel, and the top end panel to be rotated about 90° relative to the top panel, so as to transform the foldable box into its second, three-dimensional configuration; however, this is not required. Additionally, the connection arrangements can permit the front end panels to be rotated about 180° relative to the front panel and the back end panels to be rotated about 180° relative to the back panel. As such, when the foldable box is in its first, unfolded configuration, the front panel, bottom panel, back panel, top panel and top end panel are designed to lay substantially flat and, in its second, three-dimensional configuration, the foldable box can be folded such that the front panel is parallel to the back panel, and the right panel is parallel to the left panel.

In another and/or alternative non-limiting aspect of the present invention, each of the bottom panel, front panel, back panel, right panel, left panel, front end panels and back end panels of the first set of panels are foldably connected in a predetermined sequence along a crease and/or fold; however, this is not required. In such a configuration, the front panel is foldably connected to the bottom panel along a first crease, the back panel is foldably connected to the bottom panel along a second crease, the right panel is foldably connected to the bottom panel along a third crease, and the left end panel is foldably connected to the bottom panel along a fourth crease; however, this is not required. Additionally, the front end panels are foldably connected to the front panel along a fifth and sixth crease, and the back end panels are foldably connected to the back panel along a seventh and eighth crease; however, this is not required. As can be appreciated, when a liner or a separate hinge or a hinge material is used, the liner or the separate hinge or the hinge material can be used to allow separate panels to be connected together and folded with respect to one another; however, this is not required.

The size and shape of each of the panels in the first set of panels is non-limiting. In one non-limiting configuration, each of the panels in the first set of panels is rectangular or square, thereby providing a substantially rectangular or square box when folded/assembled and viewed from the top plan view; however, this is not required. The first set of panels of the foldable box can include panels of one or more different sizes; however, this is not required. In one non-limiting configuration, the first set of panels comprises a bottom panel, a front panel, and a back panel which are greater in size than the left panel and right panel; however, this is not required. In another and/or alternative non-limiting configuration, the bottom panel, right panel and left panel are the same or similar in size and shape; however, this is not required.

In another and/or alternative non-limiting aspect of the present invention, the second set of panels form the lid of the foldable box. The second set of panels comprises a top panel, a front panel, a back panel, a right panel and a left panel. Generally, the second set of panels is formed from a single piece of material; however, this is not required. The size and shape of each of the panels of the second set of panels is non-limiting. In one non-limiting configuration, the top panel of the second set of panels is the same or greater than the size of the bottom panel of the first set of panels; however, this is not required. In such a configuration, the second set of panels (i.e. the lid of the foldable box) fits over the first set of panels (i.e. the base of the foldable box); however, this is not required. In another and/or or alternative non-limiting configuration, the size of the front panel, back panel, right panel and left panel of the second set of panels is less than the size of the front panel, back panel, right panel and left panel of the first set of panels, respectively; however, this is not required. In another and/or alternative non-limiting arrangement, the top panel, front panel, back panel and left and right panels are rectangular in shape; however, this is not required. The second set of panels are optionally configured to be folded such that each of the front panel, back panel, right panel and left panel extend downwardly from the top panel, thereby providing a lid which can be placed over the first set of panels which forms the base of the foldable box; however, this is not required.

In another and/or alternative non-limiting aspect of the present invention, the second set of panels is configured to be non-foldable after manufacturing; however, this is not required. In such an arrangement, one or more corner supports can be connected between the front panel and right and left panels, and similarly between the back panel and right and left panels. As such, the lid of the foldable box is a rigid, non-foldable component after manufacturing; however, this is not required. The corner supports (when used) also provide structural support and rigidity to the lid of the foldable box; however, this is not required. The size, shape and material of the corner supports are non-limiting. In one non-limiting arrangement, the material of the corner supports is a rigid material such as, for example, metal material; however, other or alternative types of materials can be used (e.g., plastic material, ceramic material, wood, etc.).

In another and/or alternative non-limiting aspect of the present invention, the first set of panels of the foldable box can optionally comprise a plurality of individual panels which can be attached (e.g., glued, taped, melted connection, hook and loop fastener, etc.) to one surface of a liner (e.g., cover, laminate material, etc.) with small gaps and/or spaces between adjacent individual panels; however, this is not required. The small gaps and/or spaces (when used) can provide the foldable connection between individual panels of the first set of panels; however, this is not required. In such a configuration, the first and second sets of panels can optionally be laminated together; however, this is not required. In such a configuration, the front panel, back panel, right panel and left panel are spaced apart from the bottom panel; however, this is not required. The small gap and/or space between the front panel, back panel, right panel and left panel can be designed to provide the foldable connection between the front panel, back panel, right panel and left panel and the bottom panel of the foldable box; however, this is not required. In one non-limiting configuration, the front panel, back panel, right panel and left panel are foldably connected at or near the side edges of the bottom panel; however, this is not required. In one non-limiting embodiment, the front panel, back panel, right panel and left panel are spaced inward a predetermined distance from the side edges of the bottom panel; however, this is not required. Generally, the space between the front panel, back panel, right panel and left panel and the bottom panel is designed to permit the front panel, back panel, right panel and left panel to rotate about 70-150° relative to the bottom panel; however, this is not required. As such, in a three-dimensional configuration, the front panel, back panel, right panel and left panel can be moved to be parallel to each other; however, this is not required.

In another and/or alternative non-limiting aspect of the present invention, the foldable box includes a protective material provided on one or more surfaces of the foldable box; however, this is not required. The type of protective material is non-limiting. The protective material can be the same or different than the lining (when used); however, this is not required. In one non-limiting configuration, the protective material is a durable paper material; however, other or alternative types of materials can be used (e.g., fabric, composition material, plastic, metal, wood, fiberglass, etc.). In one non-limiting configuration, the protective material can be applied to a second surface of the first set of panels via an adhesive (e.g., glue, tape, etc.); however, other or alternative connection arrangements can be used (melted connection, tack, staple, etc.). Alternatively, the protective material can be a layer of tape; however, this is not required. The protective material (when used) is designed to cover a majority of the second surface of the first set of panels; however, this is not required. In one non-limiting configuration, the protective material is applied to the second surface of the first set of panels such that the protective material extends at least partially over the portion of the lining which terminates at or near the perimeter of the first set of panels; however, this is not required. In addition to providing improved durability and structural rigidity to the panels of the foldable box, the protective material also provides improved support at or near the foldable connections (i.e., creases and/or folds) between panels of the first set of panels. Optionally, all of the panels includes a protective material; however, this is not required.

In another and/or alternative non-limiting aspect of the present invention, the foldable box can include a connection arrangement provided between the front and/or back panel and the left and/or right panel such that, when the foldable box is transformed into its second, three-dimensional configuration, the front and back panels can releasably connect to the left and right panels; however, this is not required. As such, the connection arrangement between the front and/or back panel and the left and/or right panel is capable of at least partially retaining the foldable box in its second, three-dimensional configuration; however, this is not required.

The type of connection arrangement used between the top end panel and the front panel is non-limiting. In one non-limiting aspect of the present invention, a rear surface of the front end panels and back end panels are configured to include a connection arrangement configured to be connected to the front surface of the right and left panels of the first set of panels; however, this is not required. In one non-limiting configuration, a snap connection arrangement is used; however, this is not required. The number of snaps used is non-limiting. In one non-limiting configuration, the front and back end panels can include one or more snaps and the left and right panels can include one or more snaps corresponding to the one or more snaps of the front and back end panels; however, this is not required. In one specific non-limiting configuration, the foldable box includes eight snaps wherein two snaps are positioned on each of the front end panels and back end panels; however, this is not required. As can be appreciated, other connection arrangements can be used (e.g., releasable adhesive, hook and loop fastener, latch, magnets, button, etc.). When two or more snaps are used, the snaps generally have opposite and/or corresponding physical features (e.g., surface projection and recess, etc.). In one non-limiting configuration, the snaps are positioned through the material of the panels, spaced apart from the edge of the panels and the lining; however, this is not required. This size, shape and configuration of the snaps are non-limiting. In one non-limiting configuration, the thickness of each snap is selected to be about the same or less than the thickness of the material of the panels such that the outside surface of each snap is flush with the outside surface of the panels; however, this is not required. In another configuration, a first panel includes one or more snaps and a second panel includes a snap that corresponds to the one or more snaps of the first panel. In another and/or alternative non-limiting configuration, when the foldable box is converted into its second, three-dimensional structure, the snaps on the rear surface of the front end panels and back end panels can at least partially hold the foldable box in its second, three-dimensional configuration by engaging with the corresponding snaps on the front surface of the right and left panels; however, this is not required.

In another and/or alternative non-limiting aspect of the present invention, the foldable box is designed to be easily and conveniently converted from a flat, unfolded configuration to a three-dimensional configuration. In operation, a user can lift one of the left and/or right panels upward towards a vertical orientation, and one of the front and or back panels upwards towards a vertical orientation. In doing so, two adjacent panels are brought into proximity. As such, the corresponding connection arrangements between the front and back end panels can be easily and conveniently connected to the corresponding connection arrangement on the left and right side panels of the foldable box; however, this is not required. When the foldable box is in its three-dimensional configuration, the foldable box can be filled with one or more items to be stored and/or held within the foldable box.

In another and/or alternative non-limiting aspect of the present invention, the foldable box can optionally be folded from its flat, unfolded configuration into a space-saving, compact configuration; however, this is not required. The compact configuration (when used) can facilitate space-saving storage and/or transport of one or more foldable boxes; however, this is not required. In one non-limiting configuration, when the compact configuration is used, the gap between the top panel and the back panel is generally designed to permit about 180° rotation, thereby accommodating the combined thicknesses of the back panel, the top panel and the left and/or right side panels; however, this is not required. In another and/or alternative non-limiting aspect of the present invention, when the first set of panels (i.e. the base portion of the foldable box) is in its compact configuration, the first set of panels fits into the bottom of the second set of panels (i.e. the lid of the foldable box) when the second set of panels is in its second, three-dimensional configuration (see for example FIG. 13); however, this is not required. This non-limiting configuration has the advantage that the foldable box, after being assembled into its folded configuration, can later be unassembled into its original unfolded position and stored within the lid of the foldable box.

In another and/or alternative non-limiting aspect of the present invention, the foldable box optionally incorporates a plurality of additional and/or optional components. For example, in one nonlimiting configuration, the left and right panels of the first set of panels include a handle; however, this is not required. For example, a handle may be provided for the purpose of allowing a user to easily and conveniently pick up, move, or put down the foldable box; however, this is not required. The type of handle is non-limiting. In one non-limiting arrangement, a handle is connected to the left and right panels via a living hinge; however, this is not required. Similarly, the size, shape and material of the handle is non-limiting. In another and/or alternative non-limiting configuration, the front panel of the first set of panels includes a bracket; however, this is not required. For example, in one non-limiting configuration, the bracket may be provided for the purpose of serving as a card holder; however, this is not required. In such a configuration, the bracket is suitable for holding one or more cards such as, for example, a name card, information card, etc.; however, this is not required. The size, shape and material of the bracket are non-limiting.

In another and/or alternative non-limiting aspect of the present invention, there is provided a method for manufacturing the foldable box in accordance with one non-limiting aspect of the present invention. As described above, the foldable box can be formed from a first set of panels and a second set of panels; however, this is not required. The method for manufacturing the foldable box of the present invention can include: 1) selecting a material suitable for use in a foldable box, 2) cutting the selected material into a first and second set of panels having a desired size and shape, 3) optionally applying a lining material to at least a first surface of the first set of panels, 4) optionally applying a lining material to at least a first surface of the second set of panels, 5) optionally applying a protective cover to at least a first surface of the first and/or second set of panels, 6) defining one or more panels within the first set of panels, 7) forming foldable connections between the one or more panels defined within the first set of panels by some means (e.g., cutting, scoring, folding the first set of panels, forming a hinge between the first set of panels, etc.), and/or 8) applying connection arrangements to one or more panels within the first set of panels. The method for manufacturing a foldable box can further comprise the steps of: a) connecting the connection arrangements between the one or more panels within the first set of panels, and/or b) connecting the second set of panels to the first set of panels to close the opening foldable box.

In another and/or alternative non-limiting aspect of the present invention, there is provided a method for transforming the foldable box of the present invention from its first, unfolded configuration to its second, three-dimensional configuration. Initially, the foldable box is provided in an unfolded configuration wherein the first set of panels is substantially flat (i.e., the bottom panel, back panel, front panel, left panel and right panel foldable connections are all at approximately 180°). The left and right panels can be lifted upwards, thereby rotating the left and right panels relative to the bottom panel. Next, the back and front panels of the first set of panels can be lifted upwards, thereby rotating the back and front panels relative to the bottom panel. The left and right panels and the front and back panels are lifted upwards until they reach an approximately vertical position (i.e., about 90° relative to the bottom panel) wherein the connection arrangement of front and back end panels are brought into proximity with the corresponding connection arrangement of the left and right panels. The front and back end panels can then be rotated relative to the front and back panels, respectively, such that the connection arrangement on the front and back end panels engage the corresponding connection arrangements on the left and right panels. The engagement between the corresponding connection arrangements thereby foims a releasable connection. For example, when one or more connectors (e.g., snaps, magnets, hooks, etc.) are provided on the front and back end panels and are caused to engage one or more corresponding connectors (e.g., snaps, magnet, hook and loop fastener, etc.) provided on or in the other panel of the foldable box, the physical interaction between the one or more connection arrangements on the front and back end panels is sufficient to releasably and securely close the foldable box in a three-dimensional configuration.

The foldable box is foldable between one or more interchangeable configurations, and can be easily and conveniently transformed therebetween. As illustrated in FIGS. 31-39, the foldable box can be used as a magazine file box; however, the foldable box can be used for other or alternative applications. In one non-limiting aspect of the present invention, the foldable box has a first, unfolded configuration in which the foldable box is substantially flat, and a second, folded and/or three-dimensional configuration in which the foldable box is fully assembled. The first configuration (i.e., the flat, unfolded foldable box) can be easily and conveniently transformed into the second configuration (i.e., the folded, three-dimensional foldable box), and, similarly, the second configuration can be easily and conveniently transferred into the first configuration; however, this is not required.

As described above, the materials used to form the foldable box are non-limiting. Generally, the foldable box is formed from a moderately rigid material such as, for example, a heavy weight cardboard material or paperboard material; however, this is not required. As also described above, the material of the foldable box can be lined with one or more additional types of material; however, this is not required. For example, the lining (when used) completely covers a first surface of a portion of the foldable box, wraps around the perimeter thereof, and terminates at a position at or near the perimeter on a second surface of the portion of the foldable box; however, this is not required. The lining can be used to connect together one or more pieces of the foldable box (e.g., connect together multiple pieces of paperboard panels that are used to form one or more sides of the foldable box, etc.), and/or be used to form a hinge or foldable region between two or more panels of the foldable box; however, this is not required.

The shape of the foldable box is non-limiting. In one non-limiting configuration, the shape of the top plan view of the foldable box in its second, three-dimensional configuration is rectangular or square; however, the shape of the top plan view of the foldable box in its first, unfolded configuration can have other shapes. From its three-dimensional configuration, the foldable box can be transformed to a substantially flat, space-saving configuration in which the one or more panels of the foldable box are stacked on top of one another; however, this is not required. The size of the foldable box in its folded and unfolded configuration is non-limiting. In one specific non-limiting configuration, the dimensions of the foldable box in its first, unfolded configuration can be about 1-28 inches in height by about 2-20 inches in width by about 1-24 inches in length; however, the foldable box can have other dimensions. In one specific non-limiting configuration, when the foldable box in the folded configuration has a top plan rectangular shape, the dimensions of the foldable box can be about 1-16 inches in height by about 2-10 inches in width by about 1-16 inches in length; however, the foldable box can have other dimensions.

In one non-limiting aspect of the present invention, the foldable box comprises a first set of panels and a second set of panels; however, this is not required. The second set of panels is designed to be foldably connected to the first set of panels; however, this is not required. This non-limiting configuration provides a non-limiting advantage in that all components of the foldable box are connected such that no further assembly is required by the end user; a common disadvantage of many existing foldable box types in is that at least one component must typically be assembled separately and connected to the remaining portion of a box. This non-limiting configuration also has the advantage that the foldable box, after being assembled into its folded configuration, can later be unassembled into its original unfolded position. Foldable boxes that require the permanent connection of one or more components during assembly cannot thereafter be unassembled into its original unfolded position without having to damage one or more portions of the foldable box.

In another and/or alternative non-limiting aspect of the present invention, the first set of panels further comprises a front panel, a back panel, a left panel and a right panel arranged in a predetermined sequence; however, this is not required. In one non-limiting configuration, the front panel, back panel, left panel and right panel are defined portions in a single piece of material; however, this is not required. Similar to the foldable boxes described above, the front panel, back panel, left panel and right panel can be defined via cutting, scoring, creasing and/or folding; however, other or alternative methods can be used. The cutting, scoring, creasing and/or folding (when used) also provides the foldable connections between adjacent panels of the first set of panels. The size and shape of the foldable connections are non-limiting. Generally, the foldable connections are designed to permit from about 1° to about 180° angles of relative rotation between adjacent panels; however, this is not required. For example, from its flat, space-saving configuration, the connection arrangements can permit the front panel to be rotated about 90° relative to the left panel, the front panel to be rotated about 90° relative to the right panel, the back panel to be rotated about 90° relative to the left panel, and the back panel to be rotated about 90° relative to the right panel, so as to transform the foldable box into its second, three-dimensional configuration; however, this is not required. As such, when the foldable box is in its second, three-dimensional configuration, the front panel is parallel to the back panel, and the right panel is parallel to the left panel.

In another and/or alternative non-limiting aspect of the present invention, each of the front panel, back panel, left panel and right panel of the first set of panels are foldably connected in a predetermined sequence along a crease and/or fold; however, this is not required. In such a configuration, the front panel is foldably connected to the left panel along a first crease, the left panel is foldably connected to the back panel along a second crease, the back panel is foldably connected to the right panel along a third crease, and the right panel is foldably connected to the front panel along a fourth crease; however, this is not required. As can be appreciated, when a liner or a separate hinge or a hinge material is used, the liner or the separate hinge or the hinge material can be used to allow separate panels to be connected together and folded with respect to one another; however, this is not required.

The size and shape of each of the panels in the first set of panels is non-limiting. In one non-limiting configuration, the size and shape of the right and left panels are the same; however, this is not required. The first set of panels of the foldable box can include panels of one or more different sizes; however, this is not required. In one non-limiting configuration, the first set of panels comprises a rectangular-shaped back panel which is greater in height than the front panel, which also has a rectangular shape; however, this is not required. In such a configuration, the foldable box allows a user easy access to the contents of the foldable box from both the front and top of the foldable box; however, this is not required.

In another and/or alternative non-limiting aspect of the present invention, the second set of panels form the bottom of the foldable box. The second set of panels comprises a first bottom panel and a second bottom panel. Generally, the first bottom panel and a second bottom panel are formed from separate pieces of material; however, this is not required. The size and shape of the first bottom panel and a second bottom panel are non-limiting. In one non-limiting configuration, the first bottom panel and a second bottom panel are rectangular in shape and formed from the same material as the first set of panels; however, this is not required. In another and/or alternative non-limiting configuration, the length of the first bottom panel is the same or similar to the length of the right and/or left panels, and the width of the first bottom panel is the same as or similar to the width of the front and/or back panels; however, this is not required. In one non-limiting configuration, the first and second bottom panels are configured to sufficiently cover the bottom of the foldable box when the foldable box is in its second, three-dimensional configuration; however, this is not required. The second set of panels are generally designed to be adhesively and/or foldably connected to the first set of panels; however, this is not required.

A lining material can optionally be applied to the first bottom panel and the second bottom panel; however, this is not required. The lining material can be applied such that a portion of the lining material extends at least partially over the lengthwise edge of the first bottom panel and the second bottom panel, thereby forming an attachment portion suitable for facilitating attachment of the first bottom panel and the second bottom panel to the first set of panels; however, this is not required. For example, the attachment portion of the first bottom panel and the second bottom panel can be connected (e.g., glue, tape, adhesive, tack, staple, melted connection, hook and loop fastener, etc.) at or near the bottom edge of the left and right panels of the first set of panels; however, this is not required. As such, the attachment portion of the second set of panels provides a foldable and adhesive connection to the first set of panels. The foldable connection between the second set of panels and the first set of panels can permit from about 1° to about 180° rotation about the foldable connection; however, this is not required.

The inherent flexibility, durability and flexibility of lining materials provides a suitable hinge and/or foldable connection of the attachment portion; however, this is not required. The attachment portions are designed to connect the first bottom panel and the second bottom panel to the left and right panels of the first set of panels to facilitate forming a base of the foldable box when the foldable box is moved to its three-dimensional configuration; however, this is not required. Furthermore, the end user does not need to apply any additional glue and/or tape to the foldable box.

The shape and size of each of the plurality of attachment portions are non-limiting. Generally, the attachment portions are the same in size and shape; however, this is not required. In one non-limiting configuration, each attachment portion comprises a generally rectangular shape. A first surface of the attachment portion can be designed to be connected to an interior surface of the left and/or right panel. In one specific non-limiting configuration, a first surface of a first attachment portion of the first bottom panel is connected to the left panel, and a first surface of a second attachment portion of the second bottom panel is connected to the right panel; however, this is not required. The type of connection used is non-limiting. For example, the outside surface of the attachment portions can be connected to the interior surface of the left and/or panel via an adhesive such as, for example, glue, tape, hook and loop fastener, melted connection, staple, tack, etc.; however, this is not required. Generally, the attachment portions can be designed to be connected along a bottom edge of the left and/or right panels; however, this is not required.

As described above, the foldable box can optionally include a second, protective liner on a second surface thereof which extends at least partially over the lining which terminates at or near the perimeter of on the second surface of the foldable box; however, this is not required.

In another and/or alternative non-limiting aspect of the present invention, the foldable box can include a connection arrangement provided between the first bottom panel and the second bottom panel such that, when the foldable box is transformed into its second, three-dimensional configuration, the first bottom panel can releasably connect to the second bottom panel; however, this is not required. As such, the connection arrangement between the first bottom panel and the second bottom panel is capable of at least partially retaining the foldable box in its second, three-dimensional configuration; however, this is not required.

The type of connection arrangement used between the first bottom panel and the second bottom panel is non-limiting. In one non-limiting aspect of the present invention, a rear surface of the first bottom panel is configured to include a connection arrangement configured to be connected to a top surface of the second bottom panel; however, this is not required. In one non-limiting configuration, a snap connection arrangement is used; however, this is not required. The number of snaps used is non-limiting. In one non-limiting configuration, the first bottom panel can include one or more snaps and the second bottom panel can include one or more snaps corresponding to the one or more snaps of the first bottom panel; however, this is not required. In one specific non-limiting configuration, the foldable box includes two snaps; however, this is not required. As can be appreciated, other connection arrangements can be used (e.g., releasable adhesive, hook and loop fastener, latch, magnets, button, etc.). When two or more snaps are used, the snaps generally have opposite and/or corresponding physical features (e.g., surface projection and recess, etc.). In one non-limiting configuration, the snaps are positioned through the material of the panels, spaced apart from the edge of the panels and the lining; however, this is not required. This size, shape and configuration of the snaps (when used) are non-limiting. In one non-limiting configuration, the thickness of each snap is selected to be about the same or less than the thickness of the material of the panels such that the outside surface of each snap is flush with the outside surface of the panels; however, this is not required. In another configuration, a first panel includes one or more snaps and a second panel includes a snap that corresponds to the one or more snaps of the first panel. In another and/or alternative non-limiting configuration, when the foldable box is converted into its second, three-dimensional structure, the snaps on the first bottom panel and the second bottom panel can at least partially hold the foldable box in its second, three-dimensional configuration by engaging of corresponding snaps; however, this is not required.

In another and/or alternative non-limiting aspect of the present invention, the foldable box optionally incorporates a plurality of additional components. For example, in one non-limiting arrangement, the front panel of the first set of panels includes a bracket; however, this is not required. For example, in one non-limiting configuration, a bracket may be provided for the purpose of serving as a card holder; however, this is not required. In such a configuration, the bracket is suitable for holding one or more cards such as, for example, a name card, information card, etc.; however, this is not required. The size, shape and material of the bracket are non-limiting. In another and/or alternative non-limiting arrangement, the back panel optionally includes a cutout and/or opening; however, this is not required. For example, the cutout and/or opening may be provided for the purpose of providing a handle by which a user can grab the foldable box; however, this is not required. The size and shape of the cutout and/or opening is non-limiting.

In another and/or alternative non-limiting aspect of the present invention, the first set of panels of the foldable box can optionally comprise a plurality of individual panels which can be attached (e.g., glued, taped, melted connection, hook and loop fastener, etc.) to one surface of a liner (e.g., cover, laminate material, etc.) with small gaps and/or spaces between adjacent individual panels; however, this is not required.

In another and/or alternative non-limiting aspect of the present invention, the foldable box is designed to be easily and conveniently converted from a three-dimensional configuration to a substantially flat, space-saving configuration. In operation, a user can disengage the connection arrangement between the first and second bottom panels and rotate the first and second bottom panels about their foldable connections such that the first and second bottom panels are parallel to the left and right panels of the first set of panels. Thereafter, a user can collapse the foldable box by causing the left and right side panels to become parallel, and the front and back panels to become parallel; however, this is not required. Similarly, in another and/or alternative non-limiting aspect of the present invention, the foldable box can be easily and conveniently converted from a space-saving configuration to a three-dimensional configuration. For example, a user can cause the foldable connections between the panels of the first set of panels to approach about perpendicular (e.g., 85-95°) such that the front panel is parallel to the back panel and the left panel is parallel to the right panel. In doing so, the first bottom panel and second bottom panel will be caused to rotate or pivot downwards to a substantially horizontal orientation via the connection arrangements connecting the first bottom panel and second bottom panel to the left and right panels, respectively. The connection arrangement (e.g., snaps) between the bottom surface of the first bottom panel and the top surface of the second bottom panel can then be caused to engage, thereby releasably securing the foldable box in its three-dimensional configuration. As such, the foldable box can be easily and conveniently changed from a space-saving configuration to a three-dimensional configuration and vice versa. When the foldable box is in its three-dimensional configuration, the foldable box can be filled with one or more items to be stored and/or held within the foldable box.

In another and/or alternative non-limiting aspect of the present invention, there is provided a method for manufacturing a foldable box in accordance with the present invention. As described above, the foldable box can be formed from a first set of panels and a second set of panels; however, this is not required. The method for manufacturing the foldable box of the present invention can include: 1) selecting a material suitable for use in a foldable box, 2) cutting the selected material into a first and second set of panels having a desired size and shape, 3) optionally applying a lining material to at least a first surface of the first set of panels, 4) optionally applying a lining material to at least a first surface of the second set of panels forming at least one attachment portion, 5) optionally applying a protective cover to at least a first surface of the first and/or second set of panels, 6) defining one or more panels within the first set of panels, 7) forming foldable connections between the one or more panels defined within the first set of panels by some means (e.g., cutting, scoring, folding the first set of panels, forming a hinge between the first set of panels, etc.), and/or 8) connecting the second and third set of panels to the first set of panels. The method for manufacturing a foldable box can further comprise the steps of: a) connecting the connection arrangements between the one or more panels within the second set of panels to one or more panels within the first set of panels, and/or b) applying a connection arrangement to one or more panels within the second set of panels.

These and other objects and advantages will become apparent to those skilled in the art upon reading and following the description taken together with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference may now be made to the drawings which illustrate various non-limiting embodiments that the invention may take in physical form and in certain parts and arrangement of parts wherein:

FIGS. 1-10 are various views of a foldable box in accordance with one non-limiting aspect of the present invention;

FIGS. 11-20 are various views of a foldable box in accordance with another non-limiting aspect of the present invention;

FIGS. 21-30 are various views of a foldable box in accordance with another non-limiting aspect of the present invention; and,

FIGS. 31-39 are various views of a foldable box in accordance with another non-limiting aspect of the present invention.

It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. 

What is claimed is:
 1. A foldable box as discussed above and/or as illustrated in FIGS. 1-40.
 2. A method of making a foldable box as discussed above and/or as illustrated in FIGS. 1-40.
 3. A method of using a foldable box as discussed above and/or as illustrated in FIGS. 1-40. 